Cutting teeth (from a flywheel)

Technical discussion on converting internal combustion to electric
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coulomb
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Cutting teeth (from a flywheel)

Post by coulomb »

For those converters that retain the gearbox and clutch, here is the way to remove the teeth from the flywheel and save a little weight and inertia:

http://www.diyelectriccar.com/forums/sh ... tcount=136

Thanks to Woodsmith of DiyElectricCar.com for this tip.

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e-ghia
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Cutting teeth (from a flywheel)

Post by e-ghia »

We machined ours on a lathe. Took off the teeth and machined the front face flat to make a nice fit with our taper-lock hub. It's hard to tell in the photo, but...


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It's the part between the clutch (right) and the profile plate (left). After machining, we took the flywheel to an automotive machinist to have it balanced. Note the drill-press marks on the outermost surface.

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Cutting teeth (from a flywheel)

Post by HeadsUp »

thanks for sharing

just wondered if you expect to be changing gear alot with that motor having such a wide torque and RPM range

could you have done away with the gearbox and clutch completely , saved alot of weight and just direct mounted an IRS diff to the electric motor from something like a WRX , your motor is reversible so you wouldnt have to turn the diff upside down , ( you might need longer axle shafts though between the CV's )

there is a thread here somewhere with photos of a barina using that method

cheers and good luck

edited to correct the use of " driveshafts" when i meant axles
Last edited by HeadsUp on Fri, 30 Oct 2009, 13:15, edited 1 time in total.

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coulomb
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Cutting teeth (from a flywheel)

Post by coulomb »

myself wrote: ... here is the way to remove the teeth from the flywheel

I have to say that when I tried this, it wasn't as easy as it looked. I had to drill quite a hole, which was hard work, and then it took a lot of bangs to get it off. But it certainly did come off. It might have been easier to just cut it off with a hacksaw.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
160 W solar, 2.5 kWh 24 V battery for lights.
Patching PIP-4048/5048 inverter-chargers.

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